Restricted accessResearch articleFirst published online 2026-3
Computational optimization of heat recovery in a combined Proton Exchange Membrane Fuel Cell (PEMFC) and Organic Rankine Cycle (ORC) system using zeotropic fluids with Non-Dominated Sorting Genetic Algorithm II (NSGA-II)
This study presents a bi-objective optimization approach to maximize net power output by integrating Proton Exchange Membrane Fuel Cell (PEMFC) and Organic Rankine Cycle (ORC) systems. The research emphasizes the role of zeotropic working fluids in recovering waste heat from the PEMFC and converting it into additional electrical power through the ORC cycle. The study begins with validating the electrochemical model of the PEMFC by comparing simulated polarization curves with experimental data. Subsequently, three working fluid combinations—R245fa/R227ea, R245fa/R123, and Isobutane/R227ea—are evaluated for the ORC system. Among these, R245fa/R227ea exhibits the highest efficiency in combined PEMFC-ORC performance and is selected for further analysis. Under optimized conditions, the integrated system achieves an 18.91% increase in net power, alongside a 7.38% improvement in the overall efficiency compared to a standalone PEMFC without heat recovery. Additionally, a notable reduction in residual heat from both the PEMFC and ORC is observed while maintaining consistent hydrogen consumption. The ORC heat release is minimized for a zeotropic mixture of 65% R245fa and 35% R227ea, making it a key criterion for selecting working fluids in PEMFC-ORC applications.
SunHQinJYanP, et al.Performance evaluation of a partially admitted axial turbine using R245fa, R123 and their mixtures as working fluid for small-scale Organic Rankine Cycle. Energy Convers Manag2018; 171: 925–935.
2.
LiYYangMMaZ, et al.Thermodynamic modeling and exergy analysis of a combined high-temperature proton exchange membrane fuel cell and ORC system for automotive applications. Int J Mol Sci2022; 23: 15813.
3.
ZhangXZhangYLiZ, et al.Zeotropic mixture selection for an Organic Rankine Cycle using a single screw expander. Energies2020; 13: 1022.
4.
AbdiHAit MessaoudeneNKolsiL, et al.Modeling and optimization of a proton exchange membrane fuel cell using particle swarm algorithm with constriction coefficient. J Therm Anal Calorim2021; 144: 1749–1759.
5.
SheshpoliMAAjarostaghiSSMDelavarMA. Thermodynamic analysis of waste heat recovery from hybrid system of proton exchange membrane fuel cell and vapor compression refrigeration cycle by recuperative Organic Rankine Cycle. J Therm Anal Calorim2019; 135: 1699–1712.
6.
AbdiHKetfiOMapengoCR, et al.Performance prediction, optimization and economic analysis of a combined PEMFC-ORC system. J Braz Soc Mech Sci Eng2024; 46: 78.
7.
HeberleFPreißingerMBrüggemannD. Zeotropic mixtures as working fluids in Organic Rankine Cycles for low-enthalpy geothermal resources. Renew Energy2012; 37: 364–370.
8.
OyewunmiOAKirmseCJWPantaleoAM, et al.Performance of working-fluid mixtures in ORC-CHP systems for different heat-demand segments and heat-recovery temperature levels. Energy Convers Manag2017; 148: 1508–1524.
9.
SatanpholKPridasawasWSuphanitB. A study on optimal composition of zeotropic working fluid in an Organic Rankine Cycle (ORC) for low grade heat recovery. Energy2017; 123: 326–339.
10.
MiaoZZhangKWangM, et al.Thermodynamic selection criteria of zeotropic mixtures for subcritical Organic Rankine Cycle. Energy2019; 167: 484–497.
11.
LinJQinGYueH. Optimization of binary zeotropic mixture working fluids for an Organic Rankine Cycle for waste heat recovery between centrifugal compressor stages. Energy Sci Eng2020; 8: 1746–1757.
12.
YaïciWEntchevETalebizadehsardariP, et al.Thermodynamic, economic and sustainability analysis of solar organic Rankine cycle system with zeotropic working fluid mixtures for micro-cogeneration in buildings. Appl Sci2020; 10: 7925.
13.
YaïciWEntchevETalebizadehsardariP, et al.Performance investigation of solar Organic Rankine Cycle system with zeotropic working fluid mixtures for use in micro-cogeneration. J Energy Resour Technol2021; 143: 090905.
14.
SadeghiSMaghsoudiPShabaniB, et al.Performance analysis and multi-objective optimization of an Organic Rankine Cycle with binary zeotropic working fluid employing modified artificial bee colony algorithm. J Therm Anal Calorim2018; 136: 1645–1665.
15.
SurindraMDCaesarendraWPrasetyoT, et al.Comparison of the utilization of 110°C and 120°C heat sources in a geothermal energy system using Organic Rankine Cycle (ORC) with R245fa, R123, and mixed-ratio fluids as working fluids. Processes2019; 7: 113.
16.
ZhouYRuanJHongG, et al.Multi-objective optimization of the basic and regenerative ORC integrated with working fluid selection. Entropy2022; 24: 902.
17.
Méndez-CruzLEGutiérrez-LimónMÁLugo-MéndezH, et al.Comparative thermodynamic analysis of the performance of an Organic Rankine Cycle using different working fluids. Energies2022; 15: 2588.
18.
ShahroozMLundqvistPNeksåP. Performance of binary zeotropic mixtures in Organic Rankine Cycles (ORCs). Energy Convers Manag2022; 266: 115783.
19.
WangSTangJLiuC, et al.Techno-economic-environmental analysis and fluid selection of transcritical Organic Rankine Cycle with zeotropic mixtures. J Clean Prod2024; 436: 140690.
20.
NondyJGogoiTK. Proposal of a proton exchange membrane fuel cell-based hybrid system: energy, exergy and economic analyses and tri-objective optimization. Int J Hydrogen Energy2024; 52: 767–786.
21.
LuXDuBZhuW, et al.Thermodynamic and dynamic analysis of a hybrid PEMFC-ORC combined heat and power (CHP) system. Energy Convers Manag2023; 292: 117408.
22.
LuXDuBZhuW, et al.Multi-criteria assessment of an auxiliary energy system for desalination plant based on PEMFC-ORC combined heat and power. Energy2024; 290: 130163.
23.
WilberforceTMuhammadI. Dynamic modelling and analysis of organic Rankine cycle power units for the recovery of waste heat from 110 kW proton exchange membrane fuel cell system. Int J Thermofluids2023; 17: 100280.
24.
AzadAFakhariIAhmadiP, et al.Analysis and optimization of a fuel cell integrated with series two-stage Organic Rankine Cycle with zeotropic mixtures. Int J Hydrogen Energy2022; 47: 3449–3472.
25.
FakhariIBehzadiAGholamianE, et al.Comparative double and integer optimization of low-grade heat recovery from PEM fuel cells employing an Organic Rankine Cycle with zeotropic mixtures. Energy Convers Manag2021; 228: 113695.
26.
WangCLiQWangC, et al.Thermodynamic analysis of a hydrogen fuel cell waste heat recovery system based on a zeotropic Organic Rankine Cycle. Energy2021; 232: 121038.
27.
LongRLiBLiuZ, et al.A hybrid system using a regenerative electrochemical cycle to harvest waste heat from the proton exchange membrane fuel cell. Energy2015; 93: 2079–2086.
28.
LiuGQinYLiM, et al.Performance analysis and optimization of a PEMFC-CAORC system based on 3D construction method of thermodynamic cycle. Energy Convers Manag2021; 247: 114730.
29.
MohammadzadehVSaboohiZOmmiF, et al.Enhancing power production: a novel hydrogen-based scheme with comprehensive analysis and AI-optimized criteria. Energy Storage2024; 6: e70013.
30.
AshrafHAbdellatifSOElkholyMM, et al.Computational techniques based on artificial intelligence for extracting optimal parameters of PEMFCs: survey and insights. Arch Comput Methods Eng2022; 29: 3943–3972.
31.
HuaZZhengZPahonE, et al.Remaining useful life prediction of PEMFC systems under dynamic operating conditions. Energy Convers Manag2021; 231: 113825.
32.
SzemerMBuchaniecSProkopT, et al.Topology-informed machine learning for efficient prediction of solid oxide fuel cell electrode polarization. Energy and AI2025; 20: 100495.
33.
GhanbariSGhasabehiMAsadiMR, et al.An inquiry into transport phenomena and artificial intelligence-based optimization of a novel bio-inspired flow field for proton exchange membrane fuel cells. Appl Energy2024; 376: 124260.
34.
ZhaoPWangJGaoL, et al.Parametric analysis of a hybrid power system using Organic Rankine Cycle to recover waste heat from proton exchange membrane fuel cell. Int J Hydrogen Energy2012; 37: 3382–3391.
35.
LiuGQinYJiD. Numerical investigation of organic fluid flow boiling for proton exchange membrane fuel cell cooling and waste heat recovery. Appl Therm Eng2023; 228: 120564.
36.
ChahartaghiMKharkeshiBA. Performance analysis of a combined cooling, heating and power system with PEM fuel cell as a prime mover. Appl Therm Eng2018; 128: 805–817.
37.
LemmonEWHuberMLMcLindenMO. NIST standard reference database 23: reference fluid thermodynamic and transport properties-REFPROP, version 9.1 Natl Std. Ref. Data Series (NIST NSRDS). Gaithersburg, MD: National Institute of Standards and Technology, 2013.
38.
ClercMKennedyJ. The particle swarm-explosion, stability, and convergence in a multidimensional complex space. IEEE Trans Evol Comput2002; 6: 58–73.
39.
SunZWangNBiY, et al.Parameter identification of PEMFC model based on hybrid adaptive differential evolution algorithm. Energy2015; 90: 1334–1341.
40.
XuSWangYWangZ. Parameter estimation of proton exchange membrane fuel cells using eagle strategy based on JAYA algorithm and Nelder-Mead simplex method. Energy2019; 173: 457–467.
41.
DebKPratapAAgarwalS, et al.A fast and elitist multiobjective genetic algorithm: NSGA-II. IEEE Trans Evol Comput2002; 6: 182–197.
